Engine Overhaul:
Complete engine disassembly, inspection, repair, and reassembly for all TJ variants.
Fuel System Service:
Fuel delivery, injection, pumps, lines, and evaporative emissions control systems.
Cooling System Repair:
Radiator, water pump, thermostat, hoses, and coolant specifications.
Exhaust System Diagnostics:
Catalytic converter, muffler, pipes, and emissions control components.
Transmission Service:
Manual (AX-5, AX-15, NV3550) and Automatic (30RH, 42RLE) transmission repair, rebuilding, and fluid specifications.
Drivetrain Components:
Transfer case (NV131, NV241), front and rear axles (Dana 30, Dana 35c, Dana 44), driveshafts, U-joints, and CV joints.
Suspension System:
Coil spring suspension, shock absorbers, control arms, sway bars, and bushings.
Steering System Repair:
Power steering pump, gear box, steering linkage, and tie rods.
Brake System Diagnostics:
Front disc brakes, rear drum or disc brakes, ABS (if equipped), master cylinder, calipers, wheel cylinders, and brake lines.
Electrical System Troubleshooting:
Battery, charging system, starter, ignition system, lighting, and accessory circuits.
Engine Control Module ECM:
ECM diagnostics, sensor testing (MAP, TPS, O2, Crank, Cam), and actuator control.
Climate Control HVACa:
Air conditioning system, heater core, blower motor, and refrigerant handling.
Body And Chassis:
Frame inspection, body panel alignment, doors, hinges, latches, and convertible top service.
Interior Trim And Components:
Dashboard, seats, carpets, interior lighting, and instrument cluster.
Safety And Restraint Systems:
Airbags (if equipped), seat belts, and chassis safety structures.
Scheduled Maintenance:
Detailed maintenance schedules and procedures for all service intervals.
Engine Repair Procedures:
Step-by-step instructions for engine rebuilds, component replacement, and timing belt/chain service (where applicable).
Transmission Rebuild:
Comprehensive guides for rebuilding both manual and automatic transmissions.
Brake Service And Replacement:
Pad, rotor, caliper, and drum replacement; bleeding procedures.
Electrical Troubleshooting Charts:
Flowcharts and diagnostic trees for common electrical issues.
Diagnostics And Testing:
Procedures for testing sensors, actuators, and control modules using multimeters and diagnostic tools.
Suspension And Steering Alignment:
Alignment procedures and specifications.
Exhaust System Repair:
Component replacement and welding procedures.
Bodywork And Paint Guidelines:
Basic guidelines for panel repair, rust prevention, and refinishing.
Convertible Top Service:
Maintenance and repair of the soft top mechanism.
Wiring Diagrams:
Detailed electrical schematics for all vehicle systems.
Torque Specifications:
Precise torque values for all fasteners and critical components.
Special Tools List:
Identification of specialized tools required for specific repairs.
Depth Of Coverage:
Comprehensive, covering from basic maintenance to complex overhauls and diagnostics.
Diagnostic Capability:
Advanced diagnostic procedures, including troubleshooting electrical and mechanical systems.
Rebuild Instructions:
Detailed instructions for rebuilding major mechanical components like engines and transmissions.
Specifications Accuracy:
Includes precise technical specifications, fluid capacities, and wear limits.
Oil Change Interval:
Every 3,000 miles or 3 months (severe duty), or 5,000 miles/6 months (normal duty) - consult specific engine manual.
Tire Rotation Interval:
Every 6,000 miles or 6 months.
Transmission Fluid Change:
Automatic: Every 30,000-60,000 miles. Manual: Check for leaks, fluid change less frequent unless experiencing issues.
Engine Oil Spec 4.0L:
SAE 10W-30 API SJ or equivalent.
Engine Oil Spec 2.5L:
SAE 10W-30 API SJ or equivalent.
Automatic Transmission Fluid Atf:
ATF+4 (Chrysler specification)
Manual Transmission Fluid Type Nv3550:
NV3550: Mopar Manual Transmission Lubricant (or equivalent GL-4 75W-90 synthetic).
Transfer Case Fluid:
NP231: ATF+4. NP241: ATF+4.
Coolant Type:
50/50 mixture of Mopar Antifreeze/Coolant (MS-9769) and distilled water.
Common Issue Death Wobble:
Serious steering and suspension instability, often caused by worn steering components (track bar, ball joints, steering stabilizer) or improper alignment.
Common Issue Oil Leaks:
Valve cover gasket, oil pan gasket, and rear main seal are common leak points.
Common Issue Radiator Failure:
Plastic tanks can crack or separate from the aluminum core.
Common Issue Exhaust Manifold Cracks:
Especially on the 4.0L, can lead to ticking noises and exhaust leaks.
Common Issue Transfer Case Chain Stretch:
Can lead to whining noises and poor 4WD engagement.
